Wall Forming Apparatus

ABSTRACT

A barrier forming system is described that includes a plurality of studs, rails and barrier reinforcement members interconnected between top and bottom plates. The interconnected studs, rails, reinforcement members, top plate and bottom plate may be precisely bent or curved in either or both the vertical and horizontal directions. The interconnected studs, rails, barrier reinforcement members, top plate, and bottom plate may be embedded in a filler material to form a curved concrete barrier having a complex geometry.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/580,300, filed on Nov. 1, 2017, the contents of which arebeing incorporated herein by reference in their entirety.

FEDERAL SPONSORSHIP

Not Applicable

JOINT RESEARCH AGREEMENT

Not Applicable

TECHNICAL FIELD

The present invention relates generally to structural multi-dimensionalinterior or exterior curved barriers such as walls and/or ceilings, andmore particularly relates to a form that utilizes a plurality of curvedstuds, rails, plates and sheathing suitable for constructing structuralload bearing barriers or walls made from pneumatically projected orapplied concrete.

BACKGROUND

In the past, construction of concrete walls has required presettingtemporary wall forms or formworks in a location where the concrete wallis desired. Concrete is then poured into the formwork and allowed tostabilize or cure before removing the form. A formwork may typicallyinclude sidewalls and steel or wood shoring to create the desired shapeof the wall. Straight concrete structures that contain planar faces,either plumb or leaning, are created using straight sidewalls andshoring. Concrete structures requiring a more unique shape have requiredmany pieces to be mitered or curved and then pieced together to createthe desired shape of the sidewalls of the formwork. Wood beams for theshoring can be cut into curved shapes with a saw, and plywood for thesidewalls can be curved easily using multiple thin layers, but cuttingand shaping the wood beams and plywood are only economical when theshape is a continuous two dimensional surface like a drum or a cone.Creating a formwork for a simple dome requires many compound shapes andfurther requires complex cutting of the plywood into an orange-peel typeof shape and then installing on formwork in a faceted manner.

Other multi-dimensional complex surfaces or curved surfaces have beencreated utilizing a custom formwork that utilizes a single sidewall andshotcrete that is sprayed onto the sidewall until a desired thickness ofthe concrete wall is established. The shape of the form work has beendefined by creating a grid work of rebar and then bending the rebar tocreate the desired shape of the wall. Additionally the sidewall may becreated to define the desired shape and then the sidewall is attached tothe rebar. A single sidewall formwork typically includes a plasticsheathing overlying the more rigid material such as plywood or foamboard. The plastic sheathing layer is utilized so that the foam board orplywood is easily removed once the concrete has cured. Once the concretecures the formwork is removed and disposed. The present inventionutilizes stud profiles and rails to define and hold the shape of thescreens or sheathing. The studs and rails of the present invention areembedded in the concrete, are not intended to be removed, and do notrequire removal or disposal. Utilizing the present invention to formcurved concrete walls further eliminates the time required to remove anddispose of the shaped plywood or foam board mold used for one side ofthe wall.

SUMMARY

Embodiments according to aspects of the invention provide a barrierforming system or apparatus that reduces the total amount of timerequired to construct a curved concrete surface or wall formed from aspray on filler material such as shotcrete. According to other aspects,the framework of steel profiles or studs, rails and wall reinforcementremain embedded in the barrier having a complex geometry. These andother embodiments according to aspects of the invention include spacedapart corrugated studs, a top plate, bottom plate, and correspondingrails. Depending upon the orientation of the invention the top andbottom plates could be construed as side to side plates. The corrugatedstuds are spaced apart and are curved to define a curvature of thebarrier or concrete wall. Similarly the corresponding rails are shapedto correspond with the curvature of the studs and further to define thecurvature of the barrier or concrete wall. The top plate is coupled totop ends of the studs and the bottom plate is coupled to bottom ends ofthe studs. The rails include a first set of rails that correspond withthe studs, wherein the set of first rails are coupled to first edges ofthe corresponding studs. Likewise the rails include a second set ofrails that correspond with the studs, wherein the set of second railsare coupled to second edges of the corresponding studs. The inner sideof the curvature of the barrier or concrete wall is defined by the firstset of rails and first edges of the studs. Also, the outer side of thecurvature of the barrier concrete wall is defined by the set of secondrails and the second edges of the studs. After the studs, top plate,bottom plate and rails are assembled, a filler material such as concreteembeds the studs and rails to create a barrier or concrete wall capableof having a curved complex geometry.

In accordance with certain aspects of the invention, the barrier formingapparatus may further include a first barrier or wall reinforcementnetwork coupled to the first edges of the studs and coupled to the firstrails. A second barrier or wall reinforcement network may be coupled tothe second rails and second edges of the studs. Both the first andsecond barrier or wall reinforcement networks may be comprised of a meshor grid network of rebar that are coupled together. The barrier or wallreinforcement networks are set or sandwiched between the rails andstuds. When a complex geometry of curves is desired, the top plate andthe bottom plate may be constructed from a corrugated plate or stud, forexample and without limitation intended, to facilitate the shaping ofthe top and bottom plate to match a desired curve. Sheathing is attachedto the first rails and retains the filler or concrete when the filler orconcrete is sprayed to embed the rails and studs.

In use, the wall forming apparatus may be used to construct a castsurface having complex geometries and curves in both the horizontal andvertical directions. The cast surface may, for example, includeconcrete, fiberglass, foam or plaster. Further, by way of example, aconcrete wall structure may be formed by determining a desiredhorizontal curvature of the concrete wall; determining a desiredvertical curvature of the concrete wall; bending a top plate and bendinga bottom plate to match the desired horizontal or vertical curvature ofthe concrete wall; bending studs and bending rails to match a desiredvertical curvature of the concrete wall; aligning the bent studs withthe top plate and bottom plate; fastening the bent studs to the topplate and the bottom plate; fastening rails to the studs; setting wallreinforcement members between the studs and rails; attaching sheathingto the first rails; and embedding the studs and rails in concrete.

This new methodology bypasses the traditional methods of castingconcrete or other materials in temporary forms. A structure of thepresent invention is created by assembling curved studs or profiles tocreate and maintain the geometry of the required barrier or wallregardless of the degree of simplicity or complexity. An example of themethodology uses curved studs or profile members which are attached totop and bottom tracks. The studs or profiles have attached to them aseries of universal clips which act as an attachment point for both therebar or other reinforcement and the outer shaped channel or rail (inthis case a hat channel but an angle or other shape can work as well).The clip size and location is designed to carry the total loads tosupport the re-bar and furring member sheathing assemblies until theform or volume is filled in with the filler material. The shapes of thestuds and rails illustrated in the drawings can be replaced by otherembodiments and materials and still create the same affect.

The accompanying drawings, which are incorporated in and constitute aportion of this specification, illustrate embodiments of the inventionand, together with the detailed description, serve to further explainthe invention. The embodiments illustrated herein are presentlypreferred; however, it should be understood, that the invention is notlimited to the precise arrangements and instrumentalities shown. For afuller understanding of the nature and advantages of the invention,reference should be made to the detailed description in conjunction withthe accompanying drawings.

DESCRIPTION OF THE DRAWINGS

In the various figures, which are not necessarily drawn to scale, likenumerals throughout the figures identify substantially similarcomponents.

FIG. 1 is an inner perspective view of a barrier forming apparatus ofthe present invention shown with one attached sheathing member;

FIG. 2 is an outer perspective view of a barrier forming apparatus ofthe present invention;

FIG. 3 is an inner perspective view of a barrier forming apparatus ofthe present invention shown with one attached sheathing member;

FIG. 4 is an inner perspective view of the barrier forming apparatus ofthe type illustrated in FIG. 3;

FIG. 5 is an inner perspective view of the barrier forming apparatus ofthe type illustrated in FIG. 3;

FIG. 6 is an inner perspective view of the barrier forming apparatus ofthe type illustrated in FIG. 3;

FIG. 7 is a left perspective view of a profiled stud of the presentinvention;

FIG. 8 is a right perspective view of a profiled stud of the typeillustrated in

FIG. 7;

FIG. 9 is a left perspective view of a profiled rail of the presentinvention;

FIG. 10 is a right perspective view of a profiled rail of the typeillustrated in FIG. 9;

FIG. 11 is a left perspective view of an alternative profiled rail ofthe present invention;

FIG. 12 is a perspective view of an attachment clip of the presentinvention;

FIG. 13 is a left side view of the barrier forming apparatus of the typeillustrated in FIG. 1;

FIG. 14 is a partial sectional perspective view of the barrier formingapparatus of the present invention;

FIG. 15 is a partial sectional left side view of a bottom portion of thebarrier forming apparatus of the present invention;

FIG. 16 is a bottom left partial sectional perspective view of a portionof the barrier forming apparatus of the present invention; and

FIG. 17 is a flowchart illustrating the process of forming a curvedconcrete wall utilizing the barrier forming apparatus of the presentinvention.

DETAILED DESCRIPTION

The following description provides detail of various embodiments of theinvention, one or more examples of which are set forth below. Each ofthese embodiments are provided by way of explanation of the invention,and not intended to be a limitation of the invention. Further, thoseskilled in the art will appreciate that various modifications andvariations may be made in the present invention without departing fromthe scope or spirit of the invention. By way of example, those skilledin the art will recognize that features illustrated or described as partof one embodiment, may be used in another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present invention alsocover such modifications and variations that come within the scope ofthe appended claims and their equivalents.

The barrier forming apparatus 10 of the present invention isparticularly well suited for creating a curved concrete wall havingcomplex geometries. Those skilled in the art will appreciate that thebarrier forming apparatus may also be utilized to form a barrier orpartition such as ceilings or domes without departing from the scope ofthe invention. Thus, references to a curved concrete wall is notintended to be limiting to a vertically extending wall but also includesother barriers and partitions including a curved dome or ceiling. Thepresent invention is further particularly well suited to reduce the timeneeded to create and construct an accurate barrier having a complexgeometry. With reference to FIGS. 1 and 2 the barrier forming apparatus10 is shown assembled with a plurality of rails 40, studs 20, andopposing grid works 92 of rebar, wherein the plurality of rails andstuds are aligned and spaced apart with top and bottom plates 60 and 70.The grid work 92 of rebar is comprised of spaced apart horizontallyoriented rebar 94 and spaced apart vertically oriented rebar 96. Theassembly of studs 20, rails 40, top plate 60, bottom plate 70 and gridworks 92 are held in place with clips 80 and fasteners. The curvatureand complex geometry of the barrier forming apparatus 10 is defined bythe curvature of the spaced apart studs 20 and rails 40. The innercurvature of the barrier forming apparatus includes sheathing attachedto the inner rails. Although the Figures illustrate only one panel ofsheathing 100 those skilled in the art will appreciate that the entireinner side may be covered with sheathing 100. Once the sheathing 100 isattached to the rails 40, pneumatically applied or sprayed filler suchas concrete 14 is applied to the structure 10 to embed the studs 20,rails 40 and rebar 90.

FIGS. 3-6 further illustrates the barrier forming assembly 10, theposition of the sheathing 100, and the suitability of the form 10 forpneumatic applied filler applications. Those skilled in the art willappreciate that the grid work or wall reinforcement 92 may comprise aseries of space apart rebar 90 or other suitable network of rods, wiremesh, or fibers. The rods are preferably tied together with wire so thatthe wall reinforcement network may be placed between the studs and railsin a secure manner to allow the spraying of the filler material. Afterthe filler is applied, the outer surface of the wall may covered with aplaster, gypsum, sheathing or other barrier finishing product. The clips80 include holes or apertures 86 that are well suited for wire, screwsor other fasteners to extend there through. The wires or screws fastenthe clips to the wall reinforcement network, the rails 40 and the studs20. The length of the clip 80 determines the thickness of the fillerinto which the barrier reinforcement network is embedded. The top plate60 includes a main body 62 and sides 64. The bottom plate 70 similarlyincludes a main body 72 and sides 74.

FIGS. 7 and 8 further illustrate the construction of a preferredcorrugated stud 20 suitable for the present invention. The stud 20includes a main body or channel member 22, substantially opposed sides24 extending upward from the main body, and inwardly extending flanges30 extending inwards from the opposing sides 24. Preformed creases 26are formed in the main body 22 and preformed crease 28 is formed in aside of the stud. The method of forming the preformed creases is furtherdescribed in U.S. Pat. Nos. 7,458,188 and 6,138,359 the entiredisclosures of which are incorporated herein by reference. The preformedcreases allow the stud to be bent to have a desired curvature. The studsmay also be twisted to provide a still further geometric complexity tothe barrier or wall. Of course bendable studs having different structuremay be utilized without departing from the scope of the invention.

FIGS. 9-11 illustrate a suitable rail 40, however, those skilled in theart will appreciate that other known hat channel or DIN rail may beutilized without departing from the scope of the invention. The rail 40includes a base 42, flange 44 and channel 46. The rail 40 may be benteither towards or away from the channel 46. In this manner, the flange44 may be placed against the wall reinforcement network or grid work 92and while matching the curvature of the outer barrier 48 or matching thecurvature of the inner barrier 50. Numeral 48 identifies the curvaturethat corresponds with an outer barrier while numeral 50 identifies thecurvature that corresponds with an inner barrier. Further, by way ofexample and without limitation intended, the rail may be constructed inaccordance with the teachings of U.S. Pat. No. 8,621,823 the entiredisclosure of which is incorporated herein by reference.

FIG. 12 illustrates a clip suitable to couple the studs, rails andsheathing while retaining a grid work of rebar in a fixed position untilthe filler such as concrete is applied and cured. Clip 80 may beattached to either the main body 62 and 72 or the sides 64 and 74corresponding to the respective top plate 60 and bottom plate 70. Clip80 may be further attached to the base 42 or flange 44 of the rail 40.Fasteners, weld, wires, screws or other known suitable fastener may beutilized to attach the clip to the corresponding parts in the desiredlocation.

FIGS. 13-16 illustrates the barrier components and how they interrelateand attach together. The corrugated, spaced apart plurality of studs 20define a curvature of the barrier such as a concrete wall. The studs 20may extend in a vertical direction and curve in only the verticaldirection or alternatively the studs may curve in the vertical directionand twist in the horizontal direction. The top plate 60 and bottom plate70 are straight when the barrier only curves in the vertical direction.When the formed barrier includes a curve in both the vertical directionand the horizontal direction (in the case of a dome, for example), thestuds are at least curved vertically and the top plate 60 and bottomplate 70 are curved and aligned in the approximately horizontaldirection. The curved top and bottom plates may be corrugated to aid inthe bending of the plates.

Those skilled in the art will appreciate that many complex barrier orwall geometries may be precisely formed utilizing the barrier formingapparatus 10 of the present invention. When the barrier formingapparatus 10 is assembled, the top plate 60 couples to top ends of theplurality of studs 20. Similarly, when the barrier forming apparatus 10is assembled, the bottom plate 70 couples to bottom ends of theplurality of studs 20. The curved studs 20 of the assembly furtherinclude curved rails that correspond with the studs, attached toopposing edges of each stud. The inner side of the curvature of thebarrier is defined by the curvature of a first plurality of rails 40attached to corresponding first edges of the studs 20. Likewise, theouter side of the curvature of the barrier is defined by the curvatureof a second plurality of rails 40 attached to corresponding second edgesof the studs 20. A first barrier reinforcement network 92 may besandwiched or set between and coupled to the first edges of the studsand the first rails. Further, a second barrier reinforcement network 92may be coupled to the second edges of the studs and coupled to thesecond rails. The sheathing 100 may be held in place and attached to thefirst plurality of rails forming the inner curve of the barrier. Clips80 may be utilized to couple the studs 20 and rails 40. Once the barrierforming apparatus 10 is assembled a filler material such as concrete ispneumatically applied to the sheathing from the outer side of thebarrier. The concrete may be of a shotcrete type and the plates, studs,rails and network of reinforcement are all embedded in the concrete.

FIG. 17 is a representative flowchart that illustrates a process 110suitable for forming a curved concrete wall having a complex geometry.Although the process is described in terms of forming a curved concretewall, those skilled in the art will appreciate that a similar processmay be utilized to form other barriers such as a curved ceiling orfiberglass filled walls without departing from the scope of theinventive process. Referring to FIG. 17, a user determines a desiredhorizontal curvature of the concrete wall 120 and a desired verticalcurvature of the wall 122. The top plate and bottom plate are bent tomatch the desired horizontal curvature of the concrete wall 124.Likewise, the studs and rails are bent to match a desired verticalcurvature of the concrete wall 126. The bent studs are spaced apart andaligned with the top plate and bottom plate. Once aligned, the bentstuds may be fastened or otherwise attached to the top plate and thebottom plate 128. A desired network of reinforcement or rebar grid isdetermined 130 the grid work is set between the studs and rails 132. Therails and studs are then fastened or otherwise attached or coupledtogether 134. An inner side of the curvature of the concrete wall isdefined by first rails and first edges of the studs. The sheathing 100is attached to the inside wall portion or the first plurality of rails40 as described above in greater detail 136. A user may then embed thestuds and rails and grid 92 in concrete 138. After the concrete ispneumatically applied the concrete may be troweled or otherwise smoothedand then allowed to cure 140.

These and various other aspects and features of the invention aredescribed with the intent to be illustrative, and not restrictive. Thisinvention has been described herein with detail in order to comply withthe patent statutes and to provide those skilled in the art withinformation needed to apply the novel principles and to construct anduse such specialized components as are required. It is to be understood,however, that the invention can be carried out by specifically differentconstructions, and that various modifications, both as to theconstruction and operating procedures, can be accomplished withoutdeparting from the scope of the invention. Further, in the appendedclaims, the transitional terms comprising and including are used in theopen ended sense in that elements in addition to those enumerated mayalso be present. Other examples will be apparent to those of skill inthe art upon reviewing this document.

What is claimed is:
 1. A barrier forming apparatus for load bearing surface structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the barrier; a top plate coupled to top ends of the studs; a bottom plate coupled to bottom ends of the studs; first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs; second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs; wherein an inner side of the curvature of the barrier is defined by the first rails and first edges of the studs; wherein an outer side of the curvature of the barrier is defined by the second rails and the second edges of the studs; and a filler material that embeds the studs and rails.
 2. The barrier forming apparatus as recited in claim 1, further including a first barrier reinforcement network coupled to the first edges of the studs and coupled to the first rails.
 3. The barrier forming apparatus as recited in claim 1, further including a second barrier reinforcement network coupled to the second edges of the studs and coupled to the second rails.
 4. The barrier forming apparatus as recited in claim 1, wherein the top plate and the bottom plate are constructed from a corrugated plate.
 5. The barrier forming apparatus as recited in claim 1, further including a sheathing attached to the first rails.
 6. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and first rails together.
 7. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and second rails together.
 8. The barrier forming apparatus as recited in claim 1, wherein the filler material is of the shotcrete type.
 9. The wall forming apparatus as recited in claim 1, wherein the inner side and outer side of the barrier are exposed above ground level.
 10. A barrier forming apparatus for concrete wall structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the concrete wall; a top plate coupled to top ends of the studs; a bottom plate coupled to bottom ends of the studs; first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs; a first wall reinforcement network coupled to the first edges of the studs and coupled to the first rails; second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs; a second wall reinforcement network coupled to the second edges of the studs and coupled to the second rails; wherein an inner side of the curvature of the concrete wall is defined by the first rails and first edges of the studs; wherein an outer side of the curvature of the concrete wall is defined by the second rails and the second edges of the studs; and concrete that embeds the studs and rails.
 11. The barrier forming apparatus as recited in claim 10, wherein the first wall reinforcement network is comprised of a mesh of rebar.
 12. The barrier forming apparatus as recited in claim 10, wherein the second wall reinforcement network is comprised of a mesh of rebar.
 13. The barrier forming apparatus as recited in claim 10, wherein the top plate and the bottom plate are constructed from a corrugated plate.
 14. The barrier forming apparatus as recited in claim 10, further including a sheathing attached to the first rails.
 15. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and first rails together.
 16. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and second rails together.
 17. The barrier forming apparatus as recited in claim 10, wherein the concrete is of the shotcrete type.
 18. The barrier forming apparatus as recited in claim 10, wherein the inner side and outer side of the concrete wall are exposed above ground level.
 19. A method of forming a barrier, the method comprising the steps of: determining a desired horizontal curvature of the barrier; determining a desired vertical curvature of the barrier; bending a top plate and bending a bottom plate to match the desired horizontal curvature of the barrier; bending studs and bending rails to match a desired vertical curvature of the barrier; aligning bent studs with the top plate and bottom plate; fastening the bent studs to the top plate and the bottom plate; fastening rails to the studs; wherein an inner side of the curvature of the barrier is defined by first rails and first edges of the studs; setting barrier reinforcement members between the studs and rails; attaching sheathing to the first rails; and embedding the studs and rails in a filler material.
 20. The method as recited in claim 19, further including the steps of smoothing the filler material and curing the filler material. 